FCC co-processing of biomass oil
Systems and methods are provided for improving product yields and/or product quality during co-processing of fast pyrolysis oil in a fluid catalytic cracking (FCC) reaction environment. The systems and methods can allow for co-processing of an increased amount of fast pyrolysis oil while reducing or minimizing coke production for a feedstock including fast pyrolysis oil and a conventional FCC feed. The reducing or minimizing of coke production can be achieved in part by adding a low molecular weight, non-ionic surfactant to the mixture of fast pyrolysis oil and conventional FCC feed.
1. A method for co-processing pyrolysis oil, comprising:
exposing a feedstock comprising
a) 21 wt % to 35 wt % of a pyrolysis oil, the pyrolysis oil comprising an oxygen content, excluding water, of 20 wt % or more,
b) 0.01 wt % to 1.0 wt % of a non-ionic surfactant having a molecular weight of 500 g/mol to 1200 g/mol, and
c) 65 wt % or more of a feed comprising 10 wt % or more of hydrogen and a T10 distillation point of 300° C. or higher,
to a catalyst in a reactor under fluid catalytic cracking conditions to form one or more liquid product fractions;
wherein the feedstock comprises a weight ratio of non-ionic surfactant to pyrolysis oil of 0.0005 to 0.0024.
2. The method of claim 1 , wherein the non-ionic surfactant has a molecular weight of 500 g/mol to 1200 g/mol.
3. The method of claim 1 , wherein the fluid catalytic cracking conditions comprise a conversion of 60 wt % or more, the conversion being calculated on a basis that excludes water from the feedstock.
4. The method of claim 1 , wherein the feedstock comprises 25 wt % to 35 wt % of the pyrolysis oil.
5. The method of claim 1 , wherein the feedstock comprises 21 wt % to 25 wt % of the pyrolysis oil.
6. The method of claim 1 , wherein the pyrolysis oil comprises 20 wt % or more of water.
7. The method of claim 6 , wherein the pyrolysis oil, including water, comprises 40 wt % or more of oxygen.
8. The method of claim 1 , wherein the pyrolysis oil, excluding water, comprises 6.0 wt % or less of hydrogen.
9. The method of claim 1 , wherein the feedstock comprises 65 wt % or more of a feed comprising 12 wt % or more of hydrogen and a T10 distillation point of 300° C. or higher.
10. The method of claim 1 , wherein the feed comprising 10 wt % or more of hydrogen further comprises a T10 distillation point of 340° C. or higher.
11. The method of claim 1 , wherein the feed comprising 10 wt % or more of hydrogen further comprises a T90 distillation point of 600° C. or less.
12. The method of claim 1 , wherein the feedstock comprises 78 wt % or less of the feed comprising 10 wt % or more of hydrogen.
13. The method of claim 1 , further comprising mixing the pyrolysis oil, the non-ionic surfactant, and the feed comprising 10 wt % or more of hydrogen prior to exposing the feedstock to the fluid catalytic cracking conditions.
14. The method of claim 13 , wherein the mixing is performed prior to the feedstock entering the reactor.
15. The method of claim 1 , wherein the non-ionic surfactant has a molecular weight of 1500 g/mol or less.
16. The method of claim 1 , wherein the non-ionic surfactant has a molecular weight of 500 g/mol to 2000 g/mol.
17. The method of claim 1 , wherein the non-ionic surfactant has a molecular weight of 500 g/mol to 1500 g/mol.
18. The method of claim 1 , wherein the feedstock comprises 0.05 wt % to 1.0 wt % of the non-ionic surfactant.
19. The method of claim 1 , wherein the one or more liquid product fractions comprise at least one of a naphtha fraction and a light cycle oil fraction.